integrated eshq mgmt system overview

7/31/2019 Integrated ESHQ Mgmt System Overview

1/25

Integrated Environment, Safety, Health & Quality

(ESHQ) Management System

(ISO14001:2004, OHSAS 18001:1999, ISO9001:2000)

An Overview


2/25

Integrated Environment Safety Health and QualityManagement System

ISO 9001: 2000- Quality Management System

ISO 14001: 2004- Environment Management System

OHSAS 18001: 1999- Occupational Health and SafetyAssessment Series


3/25

Document structure

II

III

IV

I Apex Manual

Formats, Forms, records, register,

file, correspondence& minutes

System Procedures anddepartmental procedures

applicationWIs, OCPs, Guidelines,Specifications, ESHQ MPs, LR,Aspect /Risk Register


4/25

Document Control

Limited hard Copy Distribution

All Documents available on Home Page


5/25

pyaa-varNa, saurxaa, svaasqya evaM gauNava


6/25

Integrated Environment, Safety, Health & Quality (ESHQ) Management

System

(ISO14001:2004, OHSAS 18001:1999, ISO9001:2000)

Environment, Safety, Health & Quality Policy NTPC Ltd. Vindhyachal is committed to: Generate reliable, economical and quality electric power in

eco-friendly, healthy & safe working environment inaccordance with statutory requirements & norms withcontinual improvement in performance.

Focus on Customer Satisfaction, Total Quality, Teamwork,Human Resource Development and initiative for NewTechnologies.

Promoting innovation, speed & efficient operating practicesand prevention of Pollution & Hazards.

Compliance with relevant legislation, regulations and otherrequirements as applicable.

Waste minimization, Ash Utilization maximization,developing & maintaining greenery and conservation ofNatural Resources.

Effective implementation of well recognized managementsystems

15th Dec.2006

Rev. No.: 00


7/25

Strategic Objectives

ESHQ 1 Minimise risks and Environmental Impacts due to all types ofhazards and significant Aspects at work place

ESHQ 2 Ensure greater involvement of employees in matters of ESHQthrough suggestion schemes, reward schemes, training programmes,safety circle and safety awards

ESHQ 3 Increase the use of personal protection equipments (PPEs) likesafety shoes, helmets, hand gloves etc. through stricter enforcement,

motivation, attitudinal and behavioural changes

ESHQ 4 Better management of First-Aid Boxes

ESHQ 5 Increase the number of Trained First-Aiders available in eachshift

ESHQ 6 Enhance the medical surveillance of personnel working inareas having hazardous substances like acids, alkalis, coal-dust, ash-dust and radio-active substances

ESHQ 7 Introduce and maintain a Management Information System(MIS) for reportable and non- reportable accidents and near-miss

incidents and Efficiency


8/25

Strategic Objectives cont.

ESHQ 8Generate awareness on possible occupational illnesses andrelated improvements at workplace

ESHQ 9Create greater awareness about ESHQ matters amongemployees of contractors

ESHQ 10Improve standards of maintenance in sewerage anddrainage systems

ESHQ 11Converting Organisational MoU in to Functional LevelDepartment Targets

ESHQ 12Increasing the Scope of Integrated ESHQ managementSystem

ESHQ 13Establishing Efficient ERP system

ESHQ 14Improvement in Power Generation


9/25

Generation of Electrical Power from Vindhyachal SuperThermal Power Station ( 6x210 MW + 4x 500 MW) fromcombustion of fossil fuel and supply of power to Grid

SCOPE OF CERTIFICATION


10/25

Department Objectives & Targets

Based on Strategic Objectives/ MoU

Measurable

Time Targeted

Based on Past Performance Trend


11/25

MR & Dy. MRs

AGM(O&M) as MR

DGM(C&I) as Dy. MR(Quality) for

ISO9001:2000,

DGM(EMG) as Dy. MR (EMS) forISO14001:2004

DGM (Operations) as Dy. MR(OH&S)for OHSAS 18001:1999


12/25

Internal & External Audit Plan

Internal Audit once in six months

All three systems will be audited once

Single Certification body

Yearly External Audit


13/25

REFERENCES

Standards/ Guidelines: ISO 9000: 2000 Quality Management Systems Fundamentals &

Vocabulary

ISO 9001: 2000Quality Management Systems requirements

ISO 9004: 2000Quality Management Systems

Guidelines forPerformance Improvements

ISO 14001: 2004Environmental Management System Specificationwith guidance for use

ISO 14004: 2004Environmental Management System General

guidelines on principles, systems and supporting techniques

OHSAS 18001: 1999 with 2002 rev. Occupational Health and safetyassessment series

OHSAS 18002: 2000 Guidelines for the implementation of OHSAS18001


14/25

EXCLUSIONSISO-9001: 2000

Clause 7.3 Design & Development: The Company is notinvolved in design activities mentioned in the scope. The powergenerated and supplied by the company is as per the relevantrequirements. Hence, this clause is not applicable to the activitiesof the company.

Clause 7.5.2 Validation of Special Processes: The Companydoes not have any such activities where the outputs cannot betested / verified for its conformity. Hence, This clause is notapplicable to the activities of the company

Clause 7.5.4 Customer Property: The Company does not receiveproducts, tools, or any other materials from customers forincorporation or use of it in the plant activities. Hence, this clauseis not applicable to the activities of the company.

ISO 14001: 2004 No exclusion from any clause of ISO 14001: 2004.

OHSAS 18001: 1999 No exclusion from any clause of OHSAS 18001: 1999


15/25

Common Procedure ManualS. No Title Doc. No

1 System Procedure for Control of Documents Csp/01

2 System Procedure for Control of Records Csp/02

3 System Procedure for Internal Audit Csp/03

4 System Procedure for Control of Accidents, Incidents, non-conformances Csp/04

5 System Procedure for Corrective and Preventive Actions Csp/05

6 System Procedure for Identification of Legal and other requirements Csp/06

7 System Procedure for Hazard identification, risk assessment, risk control, identification and

analysis of critical tasks

Csp/07

8 System Procedure for Environmental Aspect And Impact Analyses Csp/08

9 System Procedure for Consultation & Communication Csp/09

10 System Procedure for Operational Control Csp/10

11 System Procedure for Emergency Preparedness And Response Csp/11

12 System Procedure for Performance Measurement And Monitoring Csp/12

13 System Procedure for Management Review Csp/03


16/25

Departments Covered under ESHQ Management system

Operation Department

Turbine Maintenance Department

C&I Department

Chemistry Department

EEMG DepartmentFuel Handling

MTP Department

FQA Department

C&M Department

Boiler Maintenance Department

Electrical Maintenance Department

Ash Handling Department

Fuel Transportation

HRD

IT Department

Health Centre

CISF

Safety

EMG

TAD

O&M Civil

TS


17/25

Competence Matrix

Sl. No. Designation MinimumEducation/

QualificationMinimumExperience

Skillsrequired Training required

1 ManagementRepresentative (MR)

Graduate

Engineer, of the

rank

Manager or

higher

15 yrs in

NTPCKnowledge

over the

business

process of the

organization,Communicati

on Skills.

Internal Auditors

Training on

ISO9001: 2000,

ISO14001:2004

OHSAS18001:1999

2 Dy. ManagementRepresentative

Graduate

Engineer, of the

rank

Manager or

higher

10 yrs in

NTPCKnowledge

over the

business

process of the

organization,Communicati

on Skills.

Internal Auditors

Training on

ISO9001: 2000,

ISO14001:2004

OHSAS18001:1999

3 Internal Auditors Executives ofthe rank E1 and

above

2 yrs in

NTPCGood

Communicati

on Skills

Internal Auditors

Training on

ISO9001: 2000,

ISO14001:2004

OHSAS18001:1999


18/25

Sl.No Document Review Approval Modification Records Issue1 Apex Manual MR/

Dy. MR

(Quality)

Dy. MR

(EMS)

Dy. MR

(OH&S)

G.M. G.M. MR MR

2 IntegratedESHQ Policy

MR/

Dy. MR

(Quality)

Dy. MR

(EMS)

Dy. MR

(OH&S)

G.M. G.M. MR MR

3 DepartmentManuals

Concerned

Sectional HeadConcerned

HODConcerned

HODConcerned HOD or

his NomineeMR

4 Objectives &Targets

Concerned


HODConcerned

HODConcerned HOD or

his NomineeMR

5 ManagementPrograms

Concerned


HODConcerned

HODConcerned HOD or

his NomineeMR

DOCUMENT MATRIX


19/25

8 Legal AspectRegister (EMS)

HOD (EMG) HOD (EMG) HOD (EMG) MR ConcernedHOD

9 Legal AspectRegister

(OH&S)

HOD (Safety) HOD (Safety) HOD (Safety) MR ConcernedHOD

10 Environment

Aspect Register

Concerned

Sectional Head/Dy. MR(EMS)

MR Concerned

HOD

MR Concerned

HOD

11 Risk AssessmentWork Sheet

Concerned

Sectional Head

Dy.

MR(OH&S)

MR ConcernedHOD

MR ConcernedHOD

12 Forms/ Formats

& Log Books

Concerned

Sectional Head

Concerned

HOD

Concerned

HOD

Concerned

HOD or hisNominee

Concerned

HOD

6 EmergencyResponse Plan

ConcernedSectional Head

ConcernedHOD

ConcernedHOD

ConcernedHOD or his

Nominee

MR

7 WorkInstructions &

Operational

Control Plans

Concerned


HODConcerned

HODConcerned

HOD or his

Nominee

Concerned

HOD


20/25

OBJECTIVES & TARGETS (FQA)

Improvement

Project/ Key

PerformanceIndicator

Unit of

MeasurementPast performance

data if applicableTarget(2006-07)

Station Availability

Factor% 92.52 89.59

Forced outage due

to Boiler Tube

Leakage

% 0.89 0.5

Accidents Reported

in DepartmentNos. - 0

Training to all

employees

Days per Employee

per Year

- 7

Example of Departmental Objectives and Targets


21/25

MANAGEMENT PROGRAMME(MP/FQA/02)Objectives & Targets: Reduction in Forced outage due toBoiler Tube Leakage

Action Plan:

Sl.No. Activity Responsibility TargetDate1 To analyse the past cases of

failures/outages

Head(FQA)

2 To decide necessarycorrective actions.

Head(FQA)

3 Monitoring regularly theeffectiveness of the

corrective actions taken.

Head(FQA)

Example of Management Programme


22/25

TITLE ROTATION OF ASH PIPE LINE (STG.1 & 2)

Work Instruction no. WI/AHM/007 Revision No.: 00Page 11of --20

Date of issue : 15th Dec2006

ROTATION OF ASH PIPELINE: Ensure proper isolation and PTW before start of work.

Mark the pipe by point, which are to be rotated. Open sleeve couplings for draining the line.

Rotate the complete length of pipe as given below by using testedpulling & lifting tools. If required cut the pipe at suitable length tofacilitate the turning.

First Rotation by 1800

Second Rotation by 900

Third Rotation by 1800

Weld the pipe after proper alignment & using proper electrodes.

Re-fix the couplings & take the trial.

Record the details in SR no.: 003/BM/ASH/007

Example of work instruction

Example of Operational Control Procedure


23/25

1.Purpose: To reduce the risk of failure of crane, chain pulley block2.Scope: ASH HANDLING

3.Responsibilities: DGM (AHM)4.Performance criteria: Reduction of instances of failure of above lifting tool.Cross reference :a)NTPC Safety rules handbook. b) Risk assessment worksheets (Ref OM-(AHM)/07)5.Activities

Sl No Activity Responsibility

01 To ensure that load test of crane & chain pulley block has beendone and the lifting load is withine the limit.

Area Engineer

02 To ensure that all protection e.g. Travel, Movement of hoistoverload and Failsafe working.

Area Engineer

03 To ensure that load is properly tied with the sling and hook. Technician

04 To ensure that chain pulley block knot are properly tied with theload.

Technician

05 Check for approach at working location Technician

06 Check illumination before start of work. Technician

07 To ensure use of safety helmets, shoes & other essential PPEs. Technician

6. Verification, Corrective & Preventive Actions:Engineer In-charge of the contract shall conduct site visits and check for deviations from laid down

procedures. Safety officer shall conduct surprise inspections.

TITLE: TO REDUCE THE RISK OF FAILURE OF

CRANE, CHAIN PULLEY BLOCK.

Work Instruction no. OCP/AHM/001Revision No.: 00

Page 15of --20

Date of issue : 15thDec2006

Example of Operational Control Procedure


24/25

NTPC VINDHYACHAL UNIT OUTAGE REPORT Page-1 of 1

Sl. Unit Trip Trip B.L.U. Syn. Outage FirstNo. No. Code Time/ Time/ Time/ Hours Cause of

Date Date Date Tripping

ANALYSIS:

Root cause:

Corrective/Preventive actions taken/being taken :

FORMAT No. SR-006/F8.5.2

Example of Format


25/25

AUDIT NO.: 02NCR NO. : AUDITOR (S) NAME (S)DEPT/ LOCATION : DATE (S) OF AUDIT :

DOCUMENT (S) USED FOR AUDITING : Apex Manual, Common Procedure Manual, WI/OCP,DM

NON-COMPLIANCE ISO9001/ ISO 14001/OHSAS 18001(DESCRIBE DEFICIENCY IN DETAIL : i.e. what ? where ? CLAUSE NO. : _______impact on Quality/Environment/Health/Safety of activity? )AUDITOR (s) AUDITEES

SIGNATURE (s) SIGNATURE

ROOT CAUSE:

CORRECTIVE ACTION :PROPOSED COMPLETION DATE ____________ AUDITEES ______________DATE____________

SIGNATURE

CORRECTIVE AND PREVENTIVE ACTION VERIFIED : YES / NO (MENTION COMMENTS)SIGNATURE DATE __________AUDITOR (S)

NCR CLOSED :REVIEWED BY : ______________________ DATE _____________

(SIGNATURE OF MR)

Format for Internal Audit